STUDY AND MODELING OF HOT TEARING FORMATION

As for most of the topics in the field of solidification, Mert Flemings has always pioneered new ideas. While much of the understanding of hot tearing formation was already known about 30 years ago, he devised with Metz an interesting apparatus for studying the resistance of mushy zones to compression and shearing [1,2]. Part of the results of these tests lead Flemings to become interested in semi-solid processing of metallic alloys, with the success we know today (e.g., production of automobile components by thixocasting). Probably because of that, hot tearing criteria and models have not progressed very much since. However, with the advent of refined stress and solidification models, one sees today renewed interest in hot tearing. The present contribution, after recollecting some of the early work of Flemings in this area, presents recent SEM observations of hot tears in aluminum alloys and in-situ observations of hot tearing formation in organic systems. A recent model of hot tearing, which combines deformation of the mushy zone and interdendritic liquid flow, is also summarized

Direct observation of hot tear formation in organic alloys

Abstract Following the work of Farup et al.

Relationship between solidification microstructure and hot cracking susceptibility for continuous casting of low-carbon and high-strength low-alloyed steels: A phase-field study

© The Minerals, Metals & Materials Society and ASM International 2013Hot cracking is one of the major defects in continuous casting of steels, frequently limiting the productivity. To understand the factors leading to this defect, microstructure formation is simulated for a low-carbon and two high-strength low-alloyed steels. 2D simulation of the initial stage of solidification is performed in a moving slice of the slab using proprietary multiphase-field software and taking into account all elements which are expected to have a relevant effect on the mechanical properties and structure formation during solidification. To account for the correct thermodynamic and kinetic properties of the multicomponent alloy grades, the simulation software is online coupled to commercial thermodynamic and mobility databases. A moving-frame boundary condition allows traveling through the entire solidification history starting from the slab surface, and tracking the morphology changes during growth of the shell. From the simulation results, significant microstructure differences between the steel grades are quantitatively evaluated and correlated with their hot cracking behavior according to the Rappaz-Drezet-Gremaud (RDG) hot cracking criterion. The possible role of the microalloying elements in hot cracking, in particular of traces of Ti, is analyzed. With the assumption that TiN precipitates trigger coalescence of the primary dendrites, quantitative evaluation of the critical strain rates leads to a full agreement with the observed hot cracking behavior. © 2013 The Minerals, Metals & Materials Society and ASM International

A phase-field model for phase transformations in glass-forming alloys

A phase-field model is proposed for phase transformations in glass-forming alloys. The glass transition is introduced as a structural relaxation, and the competition between the glass and crystalline phases is investigated. The simulations are performed for Cu-Zr alloys, employing thermodynamic and kinetic parameters derived from reported thermodynamic modeling and molecular dynamics simulation results,[1–3] respectively. Four distinct phase fields are treated with a multi-phase-field approach, representing the liquid/glass, Cu10Zr7, CuZr, and CuZr2 phases. In addition, a continuum-field method is applied to the liquid to accommodate the liquid–glass transformation. The combined phase-field approach is used to investigate the glass formation tendency, and critical cooling rates are estimated and compared with the reported experimental values

Effects of iron-rich intermetallics and grain structure on semisolid tensile properties of Al-Cu 206 cast alloys near solidus temperature

The effects of iron-rich intermetallics and grain size on the semisolid tensile properties of Al-Cu 206 cast alloys near the solidus were evaluated in relation to the mush microstructure. Analyses of the stress–displacement curves showed that the damage expanded faster in the mush structure dominated by plate-like β-Fe compared to the mush structure dominated by Chinese script-like α-Fe. While there was no evidence of void formation on the β-Fe intermetallics, they blocked the interdendritic liquid channels and thus hindered liquid flow and feeding during semisolid deformation. In contrast, the interdendritic liquid flows more freely within the mush structure containing α-Fe. The tensile properties of the alloy containing α-Fe are generally higher than those containing β-Fe over the crucial liquid fraction range of ~0.6 to 2.8 pct, indicating that the latter alloy may be more susceptible to stress-related casting defects such as hot tearing. A comparison of the semisolid tensile properties of the alloy containing α-Fe with different grain sizes showed that the maximum stress and elongation of the alloy with finer grains were moderately higher for the liquid fractions of ~2.2 to 3.6 pct. The application of semisolid tensile properties for the evaluation of the hot tearing susceptibility of experimental alloys is discussed

Электронный компас

Разработка электронного компаса на основе датчиков: магнитометра, акселерометра и гироскопа. Данное устройство будет определять направление на северный магнитный полюс как при горизонтальном положении, так и при отклонениях от горизонтальной плоскостиDevelopment of electronic compass based on sensors: magnetometer, accelerometer and gyroscope. This device will determine the direction to the North magnetic pole both in the horizontal position and in deviations from the horizontal plan

A parallel cellular automata Lattice Boltzmann Method for convection-driven solidification

This article presents a novel coupling of numerical techniques that enable three-dimensional convection-driven microstructure simulations to be con- ducted on practical time scales appropriate for small-size components or experiments. On the microstructure side, the cellular automata method is efficient for relatively large-scale simulations, while the lattice Boltzmann method provides one of the fastest transient computational fluid dynamics solvers. Both of these methods have been parallelized and coupled in a single code, allowing resolution of large-scale convection-driven solidification problems. The numerical model is validated against benchmark cases, extended to capture solute plumes in directional solidification and finally used to model alloy solidification of an entire differentially heated cavity capturing both microstructural and meso-/macroscale phenomena

Combined deformation and solidification-driven porosity formation in aluminum alloys

In die-casting processes, the high cooling rates and pressures affect the alloy solidification and deformation behavior, and thereby impact the final mechanical properties of cast components. In this study, isothermal semi-solid compression and subsequent cooling of aluminum die-cast alloy specimens were characterized using fast synchrotron tomography. This enabled the investigation and quantification of gas and shrinkage porosity evolution during deformation and solidification. The analysis of the 4D images (3D plus time) revealed two distinct mechanisms by which porosity formed; (i) deformation-induced growth due to the enrichment of local hydrogen content by the advective hydrogen transport, as well as a pressure drop in the dilatant shear bands, and (ii) diffusion-controlled growth during the solidification. The rates of pore growth were quantified throughout the process, and a Gaussian distribution function was found to represent the variation in the pore growth rate in both regimes. Using a one-dimensional diffusion model for hydrogen pore growth, the hydrogen flux required for driving pore growth during these regimes was estimated, providing a new insight into the role of advective transport associated with the deformation in the mushy region